Anti-Skid Mat

ABSTRACT

Provided herein are anti-skid mats. Generally, the anti-skid mat has a pedal layer and an anti-skid coating disposed on the bottom surface of the pedal layer. The pedal layer is a melt-blown non-woven fabric and the anti-skid coating is an acrylic layer. Alternatively, the anti-skid mat may have a release layer on the anti-skid coating.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates generally to the field of floor mats and floor tiles. More specifically, the present invention relates to an anti-skid mat comprising a machine washable, anti-bacterial pedal layer.

Description of the Related Art

Anti-skid mats have various functions. For example, anti-skid mats help to remove soil and dust from the soles of shoes when they are wiped across the mat. Mats may be water-absorbent, moisture-proof and/or anti-skid. Mats may have a decorative function when placed in entryways, hallways and rooms in dwellings and other buildings.

Various anti-skid mats are available for purchase. One common feature of many anti-skid mats is that there is a framework into which brush strips are inserted. Mats with this structure are mainly used on hallway floors with frequent entry and exit traffic by personnel, such as found in hotels, restaurants, cultural entertainment venues, conference centers, train stations, airports, and supermarkets, etc. However, due to the high cost, these mats are not suitable for use in most houses or other abodes or residences. For a household, the anti-skid mat should have a low price and provide the described features.

Anti-skid mats incorporate various materials for the anti-skid feature. For example, one anti-skid mat contains “a walnut shell rubber pad” composed of an anti-skid bottom pad and walnut shell particles attached to the anti-skid bottom pad to form a three-dimensional pattern. The anti-skid bottom pad is made of particulate rubber, recycled rubber, styrofoam, natural rubber or synthetic rubber. While using natural walnut shell instead of a man-made fabric material is environmentally beneficial, it is difficult to combine the walnut shells with the anti-skid bottom pad and easy to peel and separate the walnut shells from the anti-skid bottom. Moreover, the adhesion between rubber pad and walnut shell particles is relatively fragile, so the mat often moves when being stepped on.

An alternative anti-skid mat contains a plurality of strip rubber sheets on the bottom. The adhesion between the strip rubber sheet and the floor provides the anti-skid property. However, the strength of adhesion is limited, so there also is a risk of the mat moving and slipping when stepped on.

Another alternative anti-skid mat is a glue-coated anti-skid mat, which has an absorbent layer made of a woven fabric, a polyurethane buffer layer and a glue-coated anti-skid layer. In use the glue-coated anti-skid layer contacts the floor and the absorbent layer faces upward where one is able to stand or walk upon it. Although this arrangement increases safety, the mat is difficult to manufacture. For example, the glue-coated anti-skid layer consists of a warp-knitted mesh cloth with a hot-melt rubber coating.

In another alternative, the anti-skid mat provides a waterproof-like feature. The mat is composed of a top plush absorbent layer, a main layer, a buffer layer and a bottom anti-skid layer as placed on the floor. This mat is very suitable for children and useful in small areas, such as in kindergarten classrooms, playrooms, etc.

Therefore, the prior art is deficient in anti-skid mats that are simple in construction yet provide at least a secure anti-skid feature. Specifically, the prior art is deficient in an anti-skid mat that is easy to manufacture at a low cost and incorporates features such as increased safety, easy maintenance and ideal air permeability. The present invention fulfills this longstanding need and desire in the art.

SUMMARY OF THE INVENTION

The present invention is directed to an anti-skid mat. The anti-skid comprises a pedal layer having a top surface and a bottom surface and an anti-skid coating disposed onto the bottom surface of the pedal layer. The present invention is directed to a related anti-skid mat further comprising a release layer disposed on the anti-skid coating.

The present invention also is directed to another anti-skid mat. The anti-skid mat comprises an upper portion made of a chemical fiber, a lower portion made of an anti-skid synthetic polymer and a release layer disposed on the lower portion.

The present invention is directed further to another anti-skid mat. The anti-skid mat comprises a pedal layer with a top surface and a bottom surface formed from a melt-blown non-woven fabric, an anti-skid acrylic layer coating the bottom surface of the pedal layer; and a release layer disposed on the anti-skid acrylic layer.

Other and further aspects, features, and advantages of the present invention will be apparent from the following description of the presently preferred embodiments of the invention given for the purpose of disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the matter in which the above-recited features, advantages and objects of the invention, as well as others that will become clear, are attained and can be understood in detail, more particular descriptions of the invention briefly summarized above may be had by reference to certain embodiments thereof that are illustrated in the appended drawings. These drawings form a part of the specification. It is to be noted, however, that the appended drawings illustrate preferred embodiments of the invention and therefore are not to be considered limiting in their scope.

FIG. 1 depicts the anti-skid mat showing a pedal layer and an anti-skid coating.

FIG. 2 depicts a release later disposed on the anti-skid mat of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

As used herein in the specification, “a” or “an” may mean one or more. As used herein in the claim(s), when used in conjunction with the word “comprising”, the words “a” or “an” may mean one or more than one.

As used herein “another” or “other” may mean at least a second or more of the same or different claim element or components thereof. Similarly, the word “or” is intended to include “and” unless the context clearly indicates otherwise. “Comprise” means “include.”

As used herein, term “including” is used herein to mean “including, but not limited to”. “Including” and “including but not limited to” are used interchangeably.

As used herein, the term “about” refers to a numeric value, including, for example, whole numbers, fractions, and percentages, whether or not explicitly indicated. The term “about” generally refers to a range of numerical values (e.g., +/−5-10% of the recited value) that one of ordinary skill in the art would consider equivalent to the recited value (e.g., having the same function or result). For example, a gram weight of the pedal layer of 180 g/m² or 550 g/m² are considered within the scope of about 200 g/m² to about 500 g/m².

As used herein, the term “pedal layer” refers to the portion of the anti-skid mat where the foot or feet is placed.

As used herein, the term “release layer” refers to a removable liner, layer or sheet, for example, but not limited to, a removable paper, that protects the coating on the pedal layer prior during transportation, storage, and display for sale prior to actual use of the mat.

As used herein, the term “direct” refers to bonding the anti-skid coating to the pedal layer by direct contact, for example, via a roll coating.

As used herein, the term “indirect” refers to bonding the anti-skid coating to the pedal layer by indirect contact, for example, via spraying.

In one embodiment of the present invention, there is provided an anti-skid mat, comprising a pedal layer having a top surface and a bottom surface; and an anti-skid coating disposed onto the bottom surface of the pedal layer. Further to this embodiment the anti-skid mat comprises a release layer disposed on the anti-skid coating. Particularly, the release layer may be a paper layer.

In both embodiments, the pedal layer may comprise a melt-blown non-woven fabric made of a chemical fiber. Examples of a chemical fiber are a polyester fiber, an acrylic fiber or a polypropylene fiber. In both embodiments the anti-skid coating may be an acrylic layer. In addition, the pedal layer has a gram weight of about 200 g/m² to about 500 g/m². Furthermore, the anti-skid coating may have a gram weight of about 100 g/m² to about 300 g/m².

In another embodiment of the present invention, there is provided an anti-skid mat, comprising an upper portion made of a chemical fiber; a lower portion made of an anti-skid synthetic polymer; and a release layer disposed on the lower portion.

In this embodiment the upper portion may be a melt-blown chemical fiber formed as a pedal layer. Examples of the chemical fiber are a polyester fiber, an acrylic fiber or a polypropylene fiber. Particularly, the pedal layer may have a gram weight of about 200 g/m² to about 500 g/m². Also, in this embodiment the lower portion may be an anti-skid acrylic layer coating a bottom surface of the upper portion. Particularly, the anti-skid acrylic layer may have a gram weight of about 100 g/m² to about 300 g/m². In addition, the release layer may be a paper layer.

In yet another embodiment of the present invention, there is provided an anti-skid mat, comprising a pedal layer with a top surface and a bottom surface formed from a melt-blown non-woven fabric; an anti-skid acrylic layer coating the bottom surface of the pedal layer; and a release layer disposed on the anti-skid acrylic layer.

In this embodiment the melt-blown non-woven fabric may be a polyester fiber, an acrylic fiber or a polypropylene fiber. In this embodiment, the pedal layer may have a gram weight of about 200 g/m² to about 500 g/m². In addition, the anti-skid acrylic layer may have a gram weight of about 100 g/m² to about 300 g/m². Furthermore, the release layer may be a paper layer.

Provided herein are anti-skid mats that comprise a pedal layer and an anti-skid coating disposed thereon. A removable release layer may cover the anti-skid coating. Generally, the anti-skid mat is water-absorbent, moisture-proof and also may be decorative. The anti-skid mat is designed to be placed in hallways or onto flooring in, but not limited to, houses, apartments or other abodes, hotels, commercial buildings, entertainment venues, or other businesses.

The anti-skid mat may have any dimensions necessary to cover the desired are with one or more mats. Because the anti-skid mats remain secured to the floor even under heavy traffic, two or more mats be aligned to cover a larger area. In non-limiting examples, the width of a hallway may be covered at an entrance and/or the anti-skid mats may be extended along a hallway.

The pedal layer of the anti-skid mat comprises a chemical fiber, for example, but not limited to, a polyester fiber, a polypropylene fiber or an acrylic fiber. The anti-skid coating may be an acrylic. Production of the anti-skid mat is low cost. The chemical fiber pedal layer is formed by melt-blowing the chemical fiber as a non-woven fabric. The anti-skid coating is combined or bonded directly or indirectly with the bottom surface of the pedal layer, for example, by roll coating or by spray coating, respectively. The anti-skid mat may have a pedal layer with a gram weight of about 200 g/m² to about 500 g/m² and an acrylic coating of about 100 g/m² to about 300 g/m². The release layer may comprise a paper or paper layer that adheres to the anti-skid coating, but can be peeled from the coating prior to use of the anti-skid mat.

The anti-skid mat may be made at a low cost and the structure of the anti-skid mat provides several benefits. The melt-blown non-woven fabric that forms the pedal layer enables the dirt to be removed from the soles of shoes when the mat is stepped on and/or the soles of the shoes are wiped thereon. This keeps indoor flooring and carpets clean. The anti-skid coating or layer provides stable, full contact with the entirety of the floor on which the anti-skid mat lies. Walking over, stepping onto or wiping one's shoes on the pedal layer will therefore not cause the mat to skid or otherwise move on the floor which increases safety. The pedal layer has an ideal air permeability thereby inhibiting the proliferation and spread of bacteria. The anti-skid mat is highly flexible and can be easily washed in a household washing machine.

Particularly, embodiments of the present invention are better illustrated with reference to the Figure(s), however, such reference is not meant to limit the present invention in any fashion. The embodiments and variations described in detail herein are to be interpreted by the appended claims and equivalents thereof.

FIG. 1 illustrates the anti-skid mat 1. The mat has a pedal layer 2 and anti-skid coating 3. The pedal layer may be a melt-blown non-woven polyester fiber as shown at 2 a. The gram weight of the pedal layer 2 is about 300 g/m². The anti-skid coating is an acrylic layer with a gram weight of about 150 g/m². In an alternative embodiment the pedal layer may be a polypropylene fiber melt-blown non-woven fabric and the anti-skid coating remains an acrylic layer. The gram weight of the polypropylene fiber pedal layer is about 200 g/m² and the gram weight of the acrylic layer is about 100 g/m². In another alternative embodiment, the pedal layer is an acrylic fiber melt-blown non-woven fabric and the anti-skid coating remains an acrylic layer. The gram weight of acrylic fiber pedal layer is about 500 g/m² and the gram weight of the anti-skid coating is about 300 g/m², respectively.

With continued reference to FIG. 1, FIG. 2 shows the anti-skid mat 1 with a release layer 4. The release layer may be a paper layer and is disposed on the bottom 3 a of the anti-skid coating 3 as a removable protective layer. The release layer is placed over the anti-skid coating during product packaging and remains in place during storage, transportation and display. The release layer 4 is removed prior to placing the anti-skid mat on a floor.

The present invention is well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present invention. 

What is claimed is:
 1. An anti-skid mat, comprising a pedal layer having a top surface and a bottom surface; and an anti-skid coating disposed onto the bottom surface of the pedal layer.
 2. The anti-skid mat of claim 1, further comprising a release layer disposed on the anti-skid coating.
 3. The anti-skid mat of claim 2, wherein the release layer is a paper layer.
 4. The anti-skid mat of claim 1, wherein the pedal layer comprises a melt-blown non-woven fabric made of a chemical fiber.
 5. The anti-skid mat of claim 4, wherein the chemical fiber is a polyester fiber, an acrylic fiber or a polypropylene fiber.
 6. The anti-skid mat of claim 1, wherein the anti-skid coating is an acrylic layer.
 7. The anti-skid mat of claim 1, wherein the pedal layer has a gram weight of about 200 g/m² to about 500 g/m².
 8. The anti-skid mat of claim 1, wherein the anti-skid coating has a gram weight of about 100 g/m² to about 300 g/m².
 9. An anti-skid mat, comprising: an upper portion made of a chemical fiber; a lower portion made of an anti-skid synthetic polymer; and a release layer disposed on the lower portion.
 10. The anti-skid mat of claim 9, wherein the upper portion is a melt-blown chemical fiber formed as a pedal layer.
 11. The anti-skid mat of claim 10, wherein the chemical fiber is a polyester fiber, an acrylic fiber or a polypropylene fiber.
 12. The anti-skid mat of claim 10, wherein the pedal layer has a gram weight of about 200 g/m² to about 500 g/m².
 13. The anti-skid mat of claim 9, wherein the lower portion is an anti-skid acrylic layer coating a bottom surface of the upper portion.
 14. The anti-skid mat of claim 13, wherein the anti-skid acrylic layer has a gram weight of about 100 g/m² to about 300 g/m² in gram weight.
 15. The anti-skid mat of claim 9, wherein the release layer is a paper layer.
 16. An anti-skid mat comprising: a pedal layer with a top surface and a bottom surface formed from a melt-blown non-woven fabric; an anti-skid acrylic layer coating the bottom surface of the pedal layer; and a release layer disposed on the anti-skid acrylic layer.
 17. The anti-skid mat of claim 16, wherein the melt-blown non-woven fabric is a polyester fiber, an acrylic fiber or a polypropylene fiber.
 18. The anti-skid mat of claim 16, wherein the pedal layer has a gram weight of about 200 g/m² to about 500 g/m².
 19. The anti-skid mat of claim 16, wherein the anti-skid acrylic layer has a gram weight of about 100 g/m² to about 300 g/m².
 20. The anti-skid mat of claim 16, wherein the release layer is a paper layer. 